Suspended ceiling

ABSTRACT

A drop ceiling frame construction is provided having a circular support frame and a plurality of T-shaped frame members radially disposed from the circular support frame. At least partially disposed through the circular support frame are components selected from the group including of a light, a sensor, sprinkler head, a smoke detector, and a camera.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.62/142,003, filed on Apr. 2, 2015. The entire disclosure of the aboveapplication is incorporated herein by reference.

FIELD

The present disclosure relates to drop ceiling construction and, morespecifically, to a roll formed members for a drop-ceiling frame.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art. Traditionally, a dropceiling is constructed from a metal frame in the form of a matrix ofcircular support member 10 s which are generally of extruded or rollformed metal. The frame is used to support acoustic tile panels andlight fixtures. Drop ceiling construction has become popular in officebuilding design as they provide an architecturally pleasing appearanceand provides a space between the drop ceiling and the structural ceilingfor heating and air conditioning ducts, plumbing, and wiring.Unfortunately, access to the space between the drop ceiling and thestructural ceiling through the ceiling tile is labor intensive and candamage fire safety features.

SUMMARY

This section provides a general summary of the disclosure, and is not acomprehensive disclosure of its full scope or all of its features. Thepresent invention is directed to a drop ceiling frame construction whichcan be roll formed of sheet metal have predefined curved or circularframe members. These predefined curved or circular frame members can becoupled between adjacent straight frame members. The curved and straightmembers are supported to the ceiling structure using support rods orwires. A slot arrangement provides a mechanism of attaching predefinedcurved or circular frame members to the frame at any point along thelength of a circular support member forming the frame.

The predefined curved or circular frame members are formed by rollingsheet material to form a circular web having a predetermined radius.Coupling slots or apertures that allow the coupling of the circularflanges to linear members are formed in the web prior to or aftershaping the web. A circular support surface is coupled to the when usingben flanges, adhesive, or flanges. The slots extend in a directiontransverse to the radial axis of the predefined curved or circular framemembers. Linear members radiate from the circular frame and are combinedto form a grid pattern.

A drop ceiling frame construction is provided having a circular supportframe and a plurality of T-shaped frame members radially disposed fromthe circular support frame. A ceiling tile defining a straight edgeengaged with one of plurality of T-shaped frame members and a curvededge coupled to the circular support frame. At least partially disposedthrough the circular support frame is a component selected from thegroup including a light, a sensor, sprinkler head, a smoke detector, anda camera. The component can be fixably coupled to the circular supportframe.

According to the present teachings, a drop ceiling frame constructioncan have a first T-shaped suspended frame member and a second T-shapedsuspended frame member coupled to the first T-shaped frame member at a90 degree angle. An T- or L-shaped cross section curved support frame iscoupled to both the first and second T-shaped suspended frame members. Aceiling tile defining a first straight edge engaged with the firstT-shaped frame members and a curved surface coupled to the curvedsupport frame. The ceiling tile defines a second straight edge engagedwith the second T-shaped support frame.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected embodiments and not all possible implementations, and are notintended to limit the scope of the present disclosure.

For a better understanding of the invention, reference should be made tothe accompanying drawings, wherein:

FIG. 1 is an isometric view of a predefined curved or circular framemembers coupled to the matrix of T-frame members;

FIG. 2 is a bottom view showing the detail at an intersection between apredefined curved or circular frame members and a pair of cross members;

FIGS. 3A and 3B are sectional views taken substantially on the line 3-3of FIG. 2;

FIG. 4 is a sectional view taken substantially on the line 4-4 of FIG.2;

FIG. 5 represents an alternate embodiment of the present teachings; and

FIG. 6 represents a section of the embodiment shown in FIG. 6.

Corresponding reference numerals indicate corresponding parts throughoutthe several views of the drawings.

DETAILED DESCRIPTION

Example embodiments will now be described more fully with reference tothe accompanying drawings. FIG. 1 is an isometric view of a predefinedcurved or circular frame member 10 coupled to the matrix of linearT-shaped frame members 12 to form the frame of a drop ceiling 14. Thepredefined curved or circular frame member 10 is roll formed to apredetermined radius from a single layer of metal sheet or folded alongitudinal strip of sheet metal material, such as aluminum or steel.The members can be roll formed into any desired length by conventionalroll forming techniques.

The curved 10 and linear T-shaped frame members 12 members are supportedto the ceiling structure using support rods or wires 18. A slotarrangement provides a mechanism of attaching predefined curved orcircular frame members 10 to the linear T-shaped frame members 12 at anypoint along the length of a linear T-shaped frame member 12 forming theframe. Alternatively, the circular frame members 10 can be located as acentral support location at the intersection of two, three, or fourlinear T-shaped frame members 12.

The sheet metal is formed to provide a web section 20 of the circularframe members 10 consisting of two layers of the sheet metal normallylying in intimate contact. The upper edge 22 of the web section 20 canbe formed into a deformed channel or box frame section 24 thatstrengthens the upper edge 22 of the web section against lateralbending. Folding the sheet metal to bring the sheet metal back togetherto form the two layers of the web sections can form the section 24.

At the lower edge of the web section 26, the sheet metal layers can bebent outwardly and then downwardly to form a perpendicular ceilingsupport section. Alternatively, a circular support surface is coupled tothe when using ben flanges, adhesive, or flanges.

FIGS. 2-4, show a bottom view showing the detail at an intersectionbetween a predefined curved or circular frame members and a pair ofcross members shown in FIG. 1. The intersection is formed by two linearT-shaped frame members 12, which are in axial alignment with each otherand extend perpendicular to the circular support member 10. As best seenin FIG. 4, the ends of the abutting cross members 12 and 12′ are shapedto fit the cross-sectional contour of the circular support member 10.Once coupled to the web portion, the circular support member can have agenerally L-shaped or T-shaped cross section. At the web portion of thecircular support member 10, a vertical slot receives extensions ortongues that project from the ends of the respective T-shaped framemembers 12. The tongues hold the T-shaped frame members 12 in alignmentand at the same time lock the cross members to the circular supportmember 10.

As best seen in FIG. 2, the support sections, for the circular supportmember 10, and T-shaped linear frame members 12, are held in abuttingrelationship with the edge of the circular flange sections of thecircular support member 10. Thus the circular support member 10interrupts and supports the end of the T-shaped frame members 12. Inaddition to being supported at the ends, the T-shaped frame members 12and circular support member 10 are coupled to the ceiling using droprods or drop wires.

Normally square or rectangular ceiling tiles 32 can have a quarter orhalf circular cut out defined therein to allow proper mating with thecircular frame 10. The tiles are supported at their periphery by thesupport flange of the circular support member 10 and the T-shaped framemembers 12.

As best shown in FIGS. 3 and 4, the slots can be pre-formed in the sheetmetal strip before it is roll formed into the desired structural shape.The slots extend from the folded outer margin of the flange sections tothe inner deformed or box support section. The inner layers of the websections can then be dimpled or crimped along the length of the slots,to provide additional depth to the slots for the coupling members of theT-shaped frame members 12 or the suspension rods or wires.

By forming the slots prior to the formation of the radius of curvature,the structural integrity of the circular support member 10 ismaintained. At the same time, by removing the outer layer of the sheetmetal in the slots, the surface of the inner layer of the flangesections is exposed.

Decorative covers 38 can be placed within the circular frame 10. Thesedecorative covers 38 can be selectively removable from the circularframe 10. The covers 30 can have engagement surfaces that selectivelyengage with surfaces within the circular frame 10.

FIG. 5 represents an alternate embodiment of the present teachings whereT-shaped frame members 12 are coupled together to form a grid. Disposedbetween a pair of perpendicularly engaging T-shaped frame members 12 iscurved frame 10. In this embodiment, the curved frame represents about90 degrees of a complete circle. Four 90 degree curved members can beused to form a circular access point. Complementary to this structureare four ceiling tiles having semi-circular cutouts.

FIG. 6 represents a section of the embodiment shown in FIG. 5. Thesectional view shows the coupling mechanism alternate embodiment of thepresent teachings where T-shaped frame members 12 are coupled togetherto form a grid. Disposed between a pair of perpendicularly engagingT-shaped frame members 12 is curved frame 10. In this embodiment, thecurved frame represents about 90 degrees of a complete circle. Four 90degree curved members can be used to form a circular access point.Complementary to this structure are four ceiling tiles havingsemi-circular cutouts.

As shown in FIGS. 5 and 6, the drop ceiling frame construction can havea first T-shaped suspended frame member and a second T-shaped suspendedframe member coupled to the first T-shaped frame member at a 90 degreeangle. A T- or L-shaped cross section curved support frame is coupled toboth the first and second T-shaped suspended frame members. A ceilingtile defining a first straight edge engaged with the first T-shapedframe members and a curved surface coupled to the curved support frame.The ceiling tile defines a second straight edge engaged with the secondT-shaped support frame.

As shown in FIG. 5, the curved support frame has a first coupling flangedefined at a first end configured to engage the first T-shaped suspendedframe member, and a second coupling flange configured to engage thesecond T-shaped suspension frame member. The first and second T-shapedsupport frame members define coupling slots, where the first couplingflange is disposed within the coupling slot. At a second end of thecurved support frame, the second T-shaped support frame has supportsurface where the second coupling flange engages the support surface.

Additionally, to prevent rotation of the curved flange, a surface bearsagainst a side surface of the ceiling tile support flange. The curvedsupport frame member can represent a full or partial circle which can bedefined around the intersection of T-shaped members, or can be acentralized circular (See for example FIGS. 1 and 4.) having a radiallydisposed curved tile support flange and a body member defining aplurality of coupling slots. The T-shaped members have can be dividedinto a first plurality of T-shaped frame members and a second pluralityof T-shaped frame members each having a coupling flange coupled to oneof the plurality of coupling slots, wherein said first and secondplurality of T-shaped frame members defining a grid pattern.

The curved support frame members are a circular member having a radiallydisposed support tile support flange. The System can have a ceiling tilehaving a first straight edge coupled to one of the second T-shaped framemembers, and the ceiling tile can defining a second curved surfaceengaged to the radially disposed curved tile support flange, and acomponent at least partially disposed through the circular support framethe component selected from the group consisting of a light, a sensor,sprinkler head, a smoke detector, a camera.

This intersection construction provides the effect of continuousintersecting supports while forming a rigid ceiling grid structurehaving access to the space above the ceiling tiles. The foregoingdescription of the embodiments has been provided for purposes ofillustration and description. It is not intended to be exhaustive or tolimit the disclosure. Individual elements or features of a particularembodiment are generally not limited to that particular embodiment, but,where applicable, are interchangeable and can be used in a selectedembodiment, even if not specifically shown or described. The same mayalso be varied in many ways. Such variations are not to be regarded as adeparture from the disclosure, and all such modifications are intendedto be included within the scope of the disclosure.

Example embodiments are provided so that this disclosure will bethorough, and will fully convey the scope to those who are skilled inthe art. Numerous specific details are set forth such as examples ofspecific components, devices, and methods, to provide a thoroughunderstanding of embodiments of the present disclosure. It will beapparent to those skilled in the art that specific details need not beemployed, that example embodiments may be embodied in many differentforms and that neither should be construed to limit the scope of thedisclosure. In some example embodiments, well-known processes,well-known device structures, and well-known technologies are notdescribed in detail.

The terminology used herein is for the purpose of describing particularexample embodiments only and is not intended to be limiting. As usedherein, the singular forms “a,” “an,” and “the” may be intended toinclude the plural forms as well, unless the context clearly indicatesotherwise. The terms “comprises,” “comprising,” “including,” and“having,” are inclusive and therefore specify the presence of statedfeatures, integers, steps, operations, elements, and/or components, butdo not preclude the presence or addition of one or more other features,integers, steps, operations, elements, components, and/or groupsthereof. The method steps, processes, and operations described hereinare not to be construed as necessarily requiring their performance inthe particular order discussed or illustrated, unless specificallyidentified as an order of performance. It is also to be understood thatadditional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” or “coupled to” another element or layer, it may bedirectly on, engaged, connected or coupled to the other element orlayer, or intervening elements or layers may be present. In contrast,when an element is referred to as being “directly on,” “directly engagedto,” “directly connected to,” or “directly coupled to” another elementor layer, there may be no intervening elements or layers present. Otherwords used to describe the relationship between elements should beinterpreted in a like fashion (e.g., “between” versus “directlybetween,” “adjacent” versus “directly adjacent,” etc.). As used herein,the term “and/or” includes any and all combinations of one or more ofthe associated listed items.

Although the terms first, second, third, etc. may be used herein todescribe various elements, components, regions, layers and/or sections,these elements, components, regions, layers and/or sections should notbe limited by these terms. These terms may be only used to distinguishone element, component, region, layer or section from another region,layer or section. Terms such as “first,” “second,” and other numericalterms when used herein do not imply a sequence or order unless clearlyindicated by the context. Thus, a first element, component, region,layer or section discussed below could be termed a second element,component, region, layer or section without departing from the teachingsof the example embodiments.

Spatially relative terms, such as “inner,” “outer,” “beneath,” “below,”“lower,” “above,” “upper,” and the like, may be used herein for ease ofdescription to describe one element or feature's relationship to anotherelement(s) or feature(s) as illustrated in the Figure s. Spatiallyrelative terms may be intended to encompass different orientations ofthe device in use or operation in addition to the orientation depictedin the Figure s. For example, if the device in the Figure s is turnedover, elements described as “below” or “beneath” other elements orfeatures would then be oriented “above” the other elements or features.Thus, the example term “below” can encompass both an orientation ofabove and below. The device may be otherwise oriented (rotated 90degrees or at other orientations) and the spatially relative descriptorsused herein interpreted accordingly.

What is claimed is:
 1. A drop ceiling frame construction comprising: acircular support frame; a plurality of T-shaped frame members radiallydisposed from the circular support frame; and a ceiling tile defining astraight edge engaged with one of plurality of T-shaped frame members.2. The drop ceiling according to claim 1 where in the ceiling tiledefines a curved edge engaged with the circular support frame.
 3. Thedrop ceiling according to claim 1 wherein the circular support frame hasan L-shaped cross-section.
 4. The drop ceiling according to claim 1wherein the circular support frame has a T-shaped cross-section.
 5. Thedrop ceiling according to claim 1 wherein the circular support frame iscoupled between adjacent straight frame members.
 6. The drop ceilingaccording to claim 1 wherein the circular support frame is supportedusing support wires.
 7. The drop ceiling according to claim 1 whereinthe circular support frame is coupled to the T-shaped frame membersusing a flange in slot coupling mechanism.
 8. The drop ceiling accordingto claim 1 further comprising a cover disposed within the circularsupport frame.
 9. The drop ceiling of claim 1 wherein the T-frame memberis formed from a single sheet metal strip.
 10. The drop ceilingaccording to claim 1 further comprising a component at least partiallydisposed through the circular support frame the component selected fromthe group consisting of a light, a sensor, sprinkler head, a smokedetector, a camera.
 11. Claim 10 where in the component is fixablycoupled to the circular support frame.
 12. A drop ceiling frameconstruction comprising: a first T-shaped suspended frame member; asecond T-shaped suspended frame member coupled to the first T-shapedframe member at a 90 degree angle; a curved support frame coupled toboth the first and second T-shaped suspended frame members; and aceiling tile defining a first straight edge engaged with the firstT-shaped frame members and a curved surface coupled to the curvedsupport frame.
 13. The drop ceiling according to claim 12 where in theceiling tile defines a second straight edge engaged with the secondT-shaped support frame. The drop ceiling according to claim 12 whereinthe curved support frame has an L-shaped cross-section. The drop ceilingaccording to claim 12 wherein the curved support frame a curved supportframe has a first coupling flange defined at a first end configured toengage the first T-shaped suspended frame member, and a second couplingflange configured to engage the second T-shaped suspension frame member.16. The drop ceiling according to claim 15 wherein the first T-shapedsupport frame defines a coupling slot and the first coupling flange isdisposed within the coupling slot.
 17. The drop ceiling according toclaim 16 wherein the second T-shaped support frame has a support surfaceand wherein the second coupling flange engages the support surface. 18.A drop ceiling frame construction comprising: a curved support framemember having a radially disposed curved tile support flange and a bodymember defining a plurality of coupling slots; a first plurality ofT-shaped frame members; a second plurality of T-shaped frame memberseach having a coupling flange coupled to one of the plurality ofcoupling slots, wherein said first and second plurality of T-shapedframe members defining a grid pattern.
 19. The drop ceiling frameconstruction according to claim 18 wherein the curved support framemember is a circular member having a radially disposed support tilesupport flange
 20. The drop ceiling frame construction according toclaim 18 comprising a ceiling tile having a first straight edge coupledto one of the second T-shaped frame members, said ceiling tile defininga second curved surface engaged to the radially disposed curved tilesupport flange, and a component at least partially disposed through thecircular support frame the component selected from the group consistingof a light, a sensor, sprinkler head, a smoke detector, a camera.